Apparatus and method for interlocking blocks

ABSTRACT

An improved block for making a horizontal, vertical, uneven and/or undulating surface has opposed upper and lower surfaces and opposed side surfaces. Sleeves extend through the block from opposed side surfaces and the sleeves on one pair of sides are at a different elevation from the sleeves at the other pair of sides. When blocks are placed to define a surface the sleeves align with sleeves in adjacent blocks and connecting ties are inserted through the sleeves to interconnect and stabilize the blocks. The blocks are preferably manufactured from concrete.

FIELD OF THE INVENTION

This invention relates to blocks used to create horizontal and verticalsurfaces and the like, and more particularly to blocks such as concretepaving blocks that incorporate a system for interlocking adjacent blocksto stabilize the blocks relative to one another.

BACKGROUND OF THE INVENTION

There are many different types of blocks used as a primary surface inhorizontal or vertical applications, including for example paving bricksto cover driveways, patios, walks, walls and the like. Other examplesinclude blocks that are used to form walls such as retaining walls anddecorative walls on patios and the like. Typically, such blocks aremanufactured from concrete or similar materials formed into desirableshapes. The blocks are placed in any desirable manner to form a surfacethat is both resilient and attractive.

The stability of a surface or a wall manufactured with blocks may beincreased by tying the blocks together in some manner. There are severalknown systems for interconnecting adjacent blocks, such as cooperativemale and female parts formed into the blocks during manufacture,keyways, and the like. In addition, some paving block systems rely uponforms placed around the periphery of the blocks to hold the blocks inplace. However, most such systems result in blocks that are difficult tomanufacture on a large-scale basis, and often the blocks haveprotrusions such as keys that are prone to breaking during transport andhandling, and periphery form systems do not perform stabilization verywell. Some retaining wall blocks are designed to have pins—typicallynylon or plastic—driven into openings formed in the blocks. The pins onone block interconnect with openings on adjacent blocks to stabilize thewall.

Another common technique for stabilizing a surface such as a driveway isto improve the stability of the grade and subgrade by providing foradequate drainage and good compaction. However, even when a grade isprepared in the best manner possible the surface of the driveway maydegrade over time with the weight of cars driven over it.

Accordingly, there is a need for a block system that allows the blocksto be interlocked to enhance stability, yet is easy to manufacture andtransport. The blocks according to the present invention are simple toassemble on the job site and are easily interconnected to one anotherwith a tie system. Blocks of various sizes may be manufactured, andmixed together on a job to create a variety of patterns for the surface.The blocks incorporate a system of sleeves that extend through theblocks and ties that extend through the sleeves and into adjacentblocks. The sleeves are arranged in a manner that allows blocks to bepositioned adjacent one another in any desired orientation and stillallow ties to be extended through adjacent blocks.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be better understood and its numerous objects andadvantages will be apparent by reference to the following detaileddescription of the invention when taken in conjunction with thefollowing drawings.

FIG. 1 is a perspective view of a single block according to the presentinvention, illustrating in broken lines the sleeves running through theblock that accept the ties that interconnect adjacent blocks.

FIG. 2 is a side elevation view of three adjacent blocks shown on agrade and tied together with ties.

FIG. 3 is a top view of the three separate blocks according to thepresent invention shown in FIG. 2, illustrating in broken lines thesleeves extending through the blocks and one tie.

FIG. 4 is a side elevation view of a single block illustrating thedimensions typically used for the positions of the sleeves in the block.

FIG. 5 is a cross sectional view through a block of the type illustratedin FIG. 1, the section taken through one of the sleeves to illustrate analternative embodiment utilizing a tapered sleeve.

FIG. 6 is a cross sectional view through a block illustrating aconnector for interconnecting ties.

FIG. 7 is a schematic cross sectional view illustrating a combination ofvertical blocks according to the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

As noted above, the present invention defines an improved block thatincorporates a system for interconnecting adjacent blocks to define asystem for use in covering either horizontal or vertical surfaces suchas patios, driveways, walls and walkways and the like. Regardless oftheir particular description, such surfaces are referred to generallyherein as “surfaces.” The blocks according to the present invention arepreferably manufactured from concrete and may be made with any type offinish, color, design and three-dimensional configuration. However,other materials may be used to manufacture blocks incorporating theinvention. As detailed below, the blocks may be placed on flat, slopedor undulating horizontal surfaces, on vertical surfaces, and virtuallyany other kind of surface topography.

With reference to FIG. 1, a typical block 10 according to the presentinvention is shown as being generally rectangular in shape and havingtherefore six surfaces, namely, upper surface 12, lower surface 14, andfour adjacent side surfaces 16, 18, 20 and 22. Relative directionalterms used herein are used with reference to the ground plane. Thus,“upper” surface 12 refers to the surface of block 10 that would be theexposed surface when the block was laid into driveway, etc. “Lower”surface 14 would thus refer to the surface opposite upper surface 12,and would be the surface that rests against the grade onto which theblock is placed. Although block 10 is shown as being generallyrectangular, the block incorporating the present invention may be ofvirtually any geometric configuration. Moreover, although the “upper”edges of the block are shown as being right angles, the corners could berounded or sculpted into any desired configuration; the rectangularshape shown in the figures is to illustrate and embody the invention andis not meant to limit its scope.

With continuing reference to FIG. 1, a pair of sleeves 30 and 32 extendsthrough block 10 from side surface 16 to opposite side surface 20.Similarly, a pair of sleeves 40 and 42 extends through block 10 fromside surface 18 to opposite side surface 22. The sleeves 30 and 32 arepositioned parallel to one another and at the same elevation in block10, and sleeves 40 and 42 are also parallel to one another buttransverse to sleeves 30 and 32. Thus, sleeves 30 and 32 are positionedin the block such that the axis through the sleeves is parallel to theplane defined by upper surface 12, and such that the axis through eachof the sleeves is equidistant from the upper surface 12. Sleeves 40 and42, which as noted are transverse to sleeves 30 and 32, are at adifferent—in this case lower—elevation from sleeves 30 and 32. Thus,sleeves 40 and 42 are positioned in block 10 such that the axis throughthe sleeves is parallel and parallel to the plane of the upper surface12, and such that the axis through the sleeves is equidistant from uppersurface 12. However, the distance from the axis through sleeve 40 toupper surface 12 is different from the distance from the axis throughsleeve 30 to the upper surface 12.

Block 10 is manufactured so that the distance between any corner and thecenter of the sleeve nearest that corner is the ½ the center-to-centerdistance between two adjacent sleeves. As shown in FIG. 1, whichincludes exemplary dimensions, the sleeves 30 and 32 are spaced apartfrom one another by a distance designated with dimension Y. In a realblock, this dimension might be 4 inches, but as detailed herein, thatactual dimension could vary widely. The distance from the axialcenterline through sleeve 30 to the corner that is defined by theintersection of sides 16 and 22 is thus ½ Y, and is identified in thedrawings with dimension X. Continuing with the example just illustratedwhere Y is 4 inches, X would be 2 inches, and the distance from theaxial centerline through sleeve 32 to the nearest corner, that is, thecorner between sides 16 and 18 would similarly be 2 inches. Thisconvention is applied to all blocks 10, regardless of their shape. Thus,if block 10 is larger than the block shown in FIG. 1 and has threesleeves on any one side, the distance between sleeves is Y and thedistance from a corner to the nearest sleeve is X, and X is ½Y. Allblocks manufactured according to the present invention are compatiblewith one another through use of this convention.

In other words, the spacing of sleeves in blocks that are designed to beused together is the same for all blocks in a set, although the spacingbetween sleeves need not be 4 inches as exemplified above and thespacing between sleeves to corners thus need not be 2 inches. The resultof this structure is that regardless of which size blocks are used, orwhen blocks of different size are used to create a surface, the sleeves(or sleeve) in one block always align with the sleeves (or sleeve) inadjacent blocks. This principal is illustrated in FIG. 3, which showsthree blocks 10, one of which is larger than the other two, and in thecase of FIG. 3, the larger block 10 is twice the size of the two otherblocks. Regardless, it may be seen that the sleeve in the two smallerblocks align with sleeve 40 in the center, larger block.

With continuing reference to FIG. 1, the distance from the centerline oraxis through sleeves 30 and 32 to upper surface 12 of block 10 isdesignated as distance Z. The distance from the centerline or axisthrough sleeves 40 and 42 to lower surface 16 of block 10 is identical,and is therefore identified with dimension Z. As detailed above,therefore, while the distance from the axis through sleeve 40 to uppersurface 12 is greater than the distance from the axis through sleeve 30to upper surface 12, the distance from the axis through sleeve 40 tolower surface 16 is equal to the distance from the axis through sleeve30 to upper surface 12—distance Z.

In the event all blocks 10 are manufactured with the same thickness(i.e., the distance measured from the upper surface 12 to the lowersurface 14), then the dimension Z may be calculated as (0.5)(blockthickness)—radius of the sleeve. This of course assumes that the sleevesare located in the block such that the sleeves are directly next to oneanother in the vertical direction in the block rather than spaced apartfrom one another. If the sleeve in this formulation is not defined byraw concrete as detailed below, but is instead defined by an insert thatbecomes part of the block, then the wall thickness of the insert isadded to the radius of the sleeve in the equation.

Again, the actual size dimensions used to make blocks 10 does not matterso long as the relative relationships between the dimensions describedabove are adhered to. Thus, it will be appreciated based on theforegoing that blocks 10 may be made of various dimensions so long asall sleeves at a first elevation are spaced the same, and all transversesleeves at a second elevation are also spaced the same. The sleeves atthe first elevation may be placed at any distance from the upper surface12, and likewise, the transverse sleeves may be placed at any distancefrom lower surface 16 so long as the transverse sleeves do not interferewith the other sleeves and so long as the distance from the sleeves tothe respective nearest upper or lower surface is equal.

Sleeves 30, 32 and 40, 42 are formed when block 10 is formed in a cast.The sleeves may be formed as an insert with actual tubing formed intothe concrete material, such as metal, plastic, PVC tubing or compositematerials, or the sleeves may be formed as raw holes in the concretematerial. As such, the sleeves define holes through the blocksregardless of whether a separate material is used to define the sleeve,or the sleeve is defined by a hole formed in the material that forms theblock. Regardless of the method used to form the sleeves, the interiordiameter of all sleeves is preferably the same. Blocks 10 are formed inmolds. When tubes such as PVC tubing are used for the sleeves, the tubesare positioned in the empty molds in the desired positions. Wet concreteis then filled into the molds. Once the concrete sets, the molds areremoved and if any excess tubing extends beyond the side surfaces of theblock, the excess is removed. Alternately, when the sleeves are formedas openings in the concrete, solid rods that are slidable in the moldsare positioned such that the rods extend through the molds in thedesired positions and orientations corresponding to the positions of thesleeves. Concrete is then poured into the molds and prior to completeset of the concrete, but after the concrete is sufficiently set and canhold its shape, the rods are removed by pulling them out of the molds.This leaves through openings in the blocks that serve as the sleeves.

The grade upon which the blocks are laid is prepared according to localcodes and building rules. Typically, the grade will be leveled and alayer of crushed and compacted gravel will suffice as the grade and willprovide a good base for the blocks.

When more than one block 10 is laid adjacent another block, the twoblocks are oriented relative to one another such that the side of theblock having the sleeves at a first elevation (e.g., 30, 32) faces theside of the adjacent block that has the sleeves at the same firstelevation. More than one block oriented next to adjacent blocks as shownin FIG. 2 thus defines a surface 35, which could be a driveway, patio orany other surface. In this way, the sleeves of one block align with thesleeves of the adjacent block. Similarly, when the blocks are thusarranged, the adjacent sides of the block have sleeves that align withsleeves at the same elevation in adjacent blocks.

With reference now to FIG. 2, three blocks 10, 100 and 200 are shown.Block 10 is identical to block 10 in FIG. 1, but blocks 100 and 200,which are of the same thickness as block 10, are ½ the size measuredaround the perimeter and thus have only one sleeve running betweenopposed sides—sleeves 102 and 104 in block 100, and sleeves 202 and 204in block 200. It may be seen that sleeves 102 in block 100, 40 and 42 inblock 10, and 202 in block 200 are at the same elevation. Thus, thedistance Z measured from the axial centerline through the sleeves to thelower surface of the blocks is the same for each of the blocks.Transverse sleeves 104, 32 and 204 on the other hand are at a differentelevation, but as described above, the distance from the axialcenterline through the sleeves to the upper surface of the blocks is Z.Accordingly, all sleeves align with sleeves in adjacent blocks asdescribed above.

With blocks laid in place as shown in FIG. 2, connecting ties, referredto herein as ties 60 are inserted through the sleeves in each block. Theconnecting ties 60 have an outside diameter that is slightly smallerthan the inside diameter of the sleeves so that the ties slide easilyinto the sleeves, yet make substantial connections along the length ofthe sleeves between the tie and the interior surface of the sleeve. Theconnecting ties 60 interconnect adjacent blocks and substantiallystabilize a group of adjacent blocks. Connecting ties 60 may bemetallic, plastic, composite or other materials and may be of sufficientlength to interconnect any two or more adjacent blocks. Alternately, theties 60 may be relatively longer so that the tie together many adjacentblocks. This is typically done on relatively large, flat surfaces. At aminimum, the ties should be long enough that they are inserted into thealigned sleeves of two adjacent blocks. This connection provides theminimum satisfactory stability to the surface.

The material used for the ties may be somewhat flexible, particularlywhen relatively long sections are used. This allows the tie to beinserted into the sleeves of many adjacent blocks even where the surfaceis undulating or uneven.

It will be understood that the diameter of ties 60 and the interiordiameter of the sleeves 30, 32, etc. may be varied so long as therelative difference between the diameter of the tie and the diameter ofthe sleeve is fairly close. As noted, this allows the ties to be easilyslid into the sleeves, yet insures good contact between the tie and thesleeve, thus insuring good stabilization of the surface.

Connecting ties 60 may also be rigid, such as with metal rods, orflexible as with steel rope or cable.

A surface covered with blocks 10 interconnected with connecting ties 60according to the present invention may be horizontal, vertical, flat orundulating. The sleeves described above serve not only to acceptconnecting ties 60, but also may serve as reinforcement for the blocks.

As detailed in FIG. 4, blocks 10 may be of many different dimensions maybe square, rectangular or otherwise. For example, a block with a sideface that is 16 inches long and with 4 inch sleeve-to-sleeve spacingwould have 4 sleeves. A 12 inch block with 4 inch sleeve to sleevespacing would have 3 sleeves, and so on.

The upper surface of the block 10 may be finished in any desired manner,such as exposed aggregate, broom finish, rough or smooth finish. Thecorners of the block may be beveled, radiused, or may be at 90 degrees.

The sleeves may be either straight tubular as shown in FIG. 1, or may betapered as illustrated in FIG. 5, where sleeve 400 in block 402increases in diameter from side 404 toward opposite side 406. Theconnecting tie 60 is shown as being anchored in sleeve 400 near side404; by anchoring the connecting tie 60 in block 402 the stability ofthe surface is increased. The connecting tie may be anchored with athreaded fastener or clamp 408 applied to the connecting tie 60externally of the sleeve 400, or with adhesives 410 and the like appliedto the interior of the sleeve 400.

It will be understood that the fastener 408 may be used with sleevesthat are not tapered. Ideally, at least one end of each connecting tie60 will be anchored to a block. When plural blocks are thusinterconnected with plural connecting ties, there will be a compressiveload placed on adjacent blocks that strengthens the surface. In thisregard, with one end of a connecting tie anchored to a block, theopposite end may be similarly connected to a block that may be adjacentor many blocks separated from the anchor block, and the opposite end maybe anchored to the associated block with the connecting tie put undertension (as with a threaded fastener such as 408). This compresses theplural blocks to provide strength.

The block 402 in FIG. 5 also illustrates and example of a block that hasa dimension Z between the centerline through sleeves 30, 32 and 33 tothe lower surface of the block is one distance (i.e., distance Z), butwhere the distance from the centerline of sleeve 400 to the opposite,upper surface of the block is different—in this case, distance M. Itwill be appreciated that with the block shown in FIG. 5, all blocks mustbe oriented appropriately for the sleeves to align in adjacent blocks,and that sleeves 30, 32 and 33 in FIG. 5 will always be oriented thesame way—that is, either toward the ground or to the upper surface. Incontrast, with the blocks illustrated in FIGS. 1 through 3, where thedistance Z is the same for all sleeves measured from the sleeves to thenearest adjacent surface, the blocks may be rotated 180 degrees so thatthe upper surface becomes the lower surface, with no effect on thealignment of the sleeves.

As illustrated in FIG. 6, two connecting ties 60′ and 60″ have threadedends that are interconnected with a threaded coupler 61. The coupler 61securely interlocks the ends of adjacent ties and further stabilizes thesurface. Other methods of attaching the ends of ties may be used, suchas welding or adhesives. When a coupler such as coupler 61 is positionedintermediately along the length of a sleeve, such as illustrated in FIG.6, the diameter of the sleeve may be stepped from a larger diameter toaccommodate the coupler, which is greater in diameter than the tie, to arelatively smaller diameter that is closer to the diameter of the tie.

Finally, in FIG. 7 a plurality of blocks 500, 502, 504, and 506 areplaced in a vertical stack on a base 508, which typically is a concretefooting. The blocks shown in FIG. 7 define a retaining wall that holdsback soil 520. Typically drain tile such as tile 522 is used to providegood drainage. Each block 500, 502, 504 and 506 may be arranged so thatit is vertically staggered relative to adjacent blocks, or some otherpattern. Regardless of the relative orientation of the blocks, each ofthe blocks has a vertically oriented sleeve 510 that aligns with thesleeve 510 in the adjacent block, and with a receiving sleeve 512 inbase 508, and each block includes a horizontally oriented sleeve 514. Aconnecting tie 516 runs through the aligned vertical sleeves and isanchored in base 508. Similarly, a horizontally oriented connecting tieextends through each sleeve 514 (shown with reference numbers 519, 524,526 and 528 in FIG. 6), as detailed above with the other embodiments.

While the present invention has been described in terms of a preferredembodiment, it will be appreciated by one of ordinary skill that thespirit and scope of the invention is not limited to those embodiments,but extend to the various modifications and equivalents as defined inthe appended claims.

1. A block comprising: an upper surface; a lower surface opposite saidupper surface; first and second opposed side surfaces; third and fourthopposed side surfaces; and a first sleeve extending through said blockfrom said first side surface to the opposed second side surface at afirst elevation, and a second sleeve extending through said block fromsaid third side surface to the opposed fourth side surface at a secondelevation that is different from the first elevation.
 2. The blockaccording to claim 1 in which the distance from a centerline through thefirst sleeve to the upper surface is equal to the distance from acenterline through the second sleeve to the lower surface.
 3. The blockaccording to claim 1 in which the distance from a centerline through thefirst sleeve to the upper surface is unequal to the distance from acenterline through the second sleeve to the lower surface.
 4. The blockaccording to claim 1 including plural first sleeves extending throughsaid block from said first side surface to the opposed second sidesurface, each of said plural first sleeves at a first elevation, andplural second sleeves extending through said block from said third sidesurface to the opposed fourth side surface, each of said plural secondsleeves at a second elevation that is different from the firstelevation.
 5. The block according to claim 4 wherein the opposed sidesurfaces meet at junctions that define block corners, and wherein thedistance from any corner to the nearest sleeve is the same.
 6. The blockaccording to claim 5 wherein the distance between any two sleeves on oneside surface of said block is twice the distance from any corner to thenearest sleeve.
 7. A surface formed from a plurality of blocks accordingto claim 1, said surface defined by plural blocks arranged adjacent oneanother such that all sleeves on any side surface on any block alignwith all sleeves on any side surface of an adjacent block.
 8. Thesurface according to claim 7 including plural ties extending throughsaid sleeves such that each tie extends into at least two adjacentblocks.
 9. The surface according to claim 8 wherein said ties haveopposed ends, and wherein at least one of the opposed ends is anchoredto a block.
 10. The surface according to claim 9 wherein both ends ofthe ties are anchored to different blocks.
 11. A rectangular blockcomprising an upper surface, a lower surface, first and second opposedside surfaces, and third and fourth opposed side surfaces to define fourcorners between said four side surfaces, at least one opening formedthrough the block extending from the first surface to the secondsurface, and at least one opening formed through the block extendingfrom the third surface to the fourth surface, the at least one openingextending from the first to the second surfaces extending transverse tothe at least one opening extending from the third to the fourthsurfaces, and each of said openings nearest a corner spaced from thenearest corner by the same distance.
 12. The rectangular block accordingto claim 11 wherein the at least one opening extending from the first tosecond side surfaces is at a first elevation and the at least oneopening extending from the third to the fourth side surfaces is at asecond elevation that is different from the first elevation.
 13. Therectangular block according to claim 12 including plural openingsextending from the first to second side surfaces.
 14. The rectangularblock according to claim 12 including plural openings extending from thethird to fourth side surfaces.
 15. The rectangular block according toclaim 14 wherein each opening extending from the first to second sidesurfaces is at the first elevation and each opening extending from thethird to fourth side surfaces is at the second elevation.
 16. A methodof providing a surface with plural blocks, comprising the steps of: (a)providing a plurality of blocks, each block in the plurality comprisingan upper surface, a lower surface, and first and second opposed sidesurfaces and third and fourth opposed side surfaces, the four sidesurfaces defining four corners at the junction of the side surfaces, anda first sleeve extending through the block from the first to the secondopposed sides, the first sleeve at a first elevation, and a secondsleeve extending through the block from the third to the fourth opposedsides, the second sleeve at a second elevation that is different fromthe first elevation; (b) arranging said plurality of blocks adjacent oneanother such that each of the first and second opposed sides of anyblock lies adjacent the first and second opposed sides of an adjacentblock and so that the first sleeve in the first block aligns with thefirst sleeve of the adjacent block; and (c) connecting adjacent blockswith a first connecting tie extending through aligned sleeves inadjacent blocks.
 17. The method according to claim 16 including the stepof connecting adjacent blocks with a second connecting tie that extendstransverse to the first connecting tie.
 18. The method according toclaim 16 including the step of anchoring at least one end of the firstconnecting tie to a block.
 19. The method according to claim 16including the step of anchoring one end of the first connecting tie to ablock, anchoring the opposite end of the first connecting tie to adifferent block, and providing tension on said connecting tie to applycompressive force to said blocks.
 20. The method according to claim 16wherein the surface covers a ground surface.